Esprit Electronics has strengthened its inspection capability with the introduction of two Koh Young Zenith 2 AOI systems, following a detailed technical evaluation of leading inspection technologies for complex PCB assembly.
Altus Group supported Esprit Electronics throughout the evaluation process, providing demonstrations and technical guidance as the engineering team assessed how measurement-based 3D inspection could deliver greater process visibility for complex electronics manufacturing.
Based across two production facilities and operating four SMT lines, Esprit Electronics manufactures complex PCB assemblies for customers in high-reliability sectors including medical, military and industrial electronics. As product complexity and quality expectations continue to increase, the company identified inspection as a key area for further investment.
Esprit’s engineering team undertook a structured review of the inspection market, comparing camera-based, laser-based and Moiré fringe-based systems. Demonstrations and trials were carried out using the same representative PCB assembly, allowing the team to assess each platform against the practical demands of its own production environment.
Rob Pembroke-Burn, Production Engineer at Esprit Electronics, said: “It was really great to get a chance to spearhead the technical review aspect of this investment, having lived and managed the challenges of our existing inspection processes. The breadth and quality of technology and the advancements are eye opening. We knew that whichever unit we selected was going to be a step up for the company, but our job was to identify the best technology among the leading platforms.”
The evaluation highlighted the Koh Young Zenith 2 AOI system as the strongest fit for Esprit’s complex PCB assemblies. The platform uses True 3D measurement technology based on Moiré interferometry, capturing precise height and volume measurements across the PCB surface rather than relying solely on two-dimensional image analysis.
For Esprit, this measurement-led approach provides a more robust method of inspecting solder joints and components across dense and varied PCB layouts, while reducing the assumptions typically associated with conventional AOI systems.
Following further technical discussions and a subsequent review, Esprit confirmed its decision to invest in two Zenith 2 systems equipped with eight-megapixel imaging, Offline Programming (OLP) capability and the KSMART Pro software platform.
The Koh Young Zenith 2 combines high-resolution optics, advanced vision algorithms and multi-projection Moiré interferometry to generate detailed 3D inspection data across the entire PCB surface. Its KSMART software environment also enables Esprit to analyse inspection data and apply statistical process control tools to support ongoing process monitoring and improvement.
Allan Hawkins, Production Engineer at Esprit Electronics, said: “What a good result! The team and I are really happy with the investment and the step up in our inspection capacity. We are excited about the impact the technology will have on our internal efficiencies and processes, but ultimately the quality we can ensure our customers receive.”